Prosthesis coupling device and method

ABSTRACT

A coupling device ( 28 ) is formed of a double tubing ( 50 ) of a substantially non-porous membrane material, typically a conventional graft material, that is of inner and outer layers of membrane material ( 52, 54 ). The inner and outer layers ( 52, 54 ) are coupled by bridging rings ( 56, 58 ) which allow the layers ( 52, 54 ) to be spaced from one another in use. Attached to the inner and outer layers ( 52, 54 ) are first and second stents ( 60, 62 ). The stent ( 60 ) is located on the inside of the double tubing, while the stent ( 62 ) is located on the outside of the double tubing ( 50 ). The device ( 28 ) can expand in effect to ‘bulge’ and thus to fill the gaps to the vessel wall and to the stent-graft sections ( 24, 26 ). The device can provide reliable coupling of stent-grafts in vessels of varying diameter or in vessels inflicted with one or more aneurysms.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a nationalization of PCT applicationPCT/US2009/000869 filed on Feb. 11, 2009. This application claims thebenefit of the filing date under 35 U.S.C. §119(e) of U.S. ProvisionalPatent Application Ser. No. 61/065,333, filed Feb. 11, 2008, which ishereby incorporated by reference.

TECHNICAL FIELD

The present invention relates to a prosthesis coupling device, to aprosthetic assembly and to a method of making a coupling device.

BACKGROUND ART

Prostheses for the repair of vascular defects, including for examplevascular aneurysms, are well known in the art. A common prosthesis fortreatment of such a medical condition is a stent graft. It is also knownto provide such prostheses in modular form, for example when it isnecessary for the prosthesis to straddle a plurality of vessels, such asthe superior mesenteric artery and the iliac arteries. Similarly, amodular prosthesis may be provided in cases where the dimensions of theartery or other vessel to be treated would vary substantially from oneend of the prosthesis to the other. Yet another example is where amedical condition necessitates the use of different types of prosthesisalong the length of the site to be treated.

It is common for such modular prostheses to be coupled together bynesting one section within the other and expanding the innermost sectionagainst the interior surface of the outer section. Such expansion can beeffected, for example, by means of a self-expanding element such as aself-expanding stent, or by a separate expansion mechanism, such as anexpandable balloon. It will be apparent that in order to obtain afluid-tight seal between the various modules of such a prosthesis thesections must have complementary dimensions at their point of coupling.This necessitates careful manufacturing and imposes consequentiallimitations on the design of the modules.

Furthermore, it is necessary in many medical treatments, such as in thetreatment of aneurysms, the bypass of occluded or otherwise damagedvessels and so on, to provide a fluid-tight seal between the ends of theprosthesis and the walls of the vessel in order to avoid blood loss.This requires the prosthesis, for example the stent-graft, to be of asuitable dimension for the particular vessel being treated. As a resultof this, a surgeon must select a suitable prosthesis size for thedimensions of the vessel as well as for the particular vesselcharacteristics at the place of implantation of the prosthesis.Particular problems can arise in the case of aneurisms, for example,where the vessel is enlarged at the ends of the prosthesis or at thepoint of coupling of two modules of a modular prosthesis.

DISCLOSURE OF THE INVENTION

The present invention seeks to provide a coupling device for aprosthesis and an improved prosthetic assembly.

According to an aspect of the present invention, there is provided acoupling device for a prosthesis including inner and outer couplingelements arranged concentrically one within the other and able to bespaced apart in the course of coupling; and a substantially non-porousmembrane associated with at least the outer coupling element; whereinthe outer coupling element is of a self-expandable form.

The coupling device is such that the outer coupling element can expandto abutment with the interior surface of a vessel wall into which thedevice is placed and, in conjunction with the membrane, can provide asubstantially fluid-tight seal against the vessel wall. The innercoupling element provides a connection location for connecting togethertwo modules of a prosthesis or other implant which, in the preferredembodiment, is not dependent upon the dimensions of the vessel in thelocation at which the device is fitted.

The inner coupling element is preferably also of a self-expandable typealthough this is not essential as the inner coupling element could beexpandable by a separate expansion mechanism such as a balloon.

Where the inner coupling element is self-expandable, this is preferablyof a size relative to the prosthesis to press there against, in otherwords of a natural, unbiased, diameter smaller than the outer diameterof the prosthesis to be coupled thereto.

In the preferred embodiment, the inner and outer coupling elements arestents. Advantageously, the membrane is of a known graft material.

It is preferred that the membrane forms part of the coupling device,although this is not essential. It is envisaged in some embodiments thatthe membrane could be a separate component, for example as a part of agraft of one of the modules to be connected by the coupling element.

Advantageously, the device includes a membrane associated with both theinner and outer coupling elements and most preferably the membrane isconnected to both of the inner and outer coupling members. In thislatter case, the membrane may be in the shape of a double concentrictube connected at either end, the inner and outer coupling elementsbeing located, respectively, on the inner and outer tube layers.

Advantageously, the membrane is a unitary structure formed of first andsecond tubular portions in which the first tubular portion has a largerdiameter than the second tubular portion and includes a taperingconnecting piece between the first and second tubular portions, thesecond tubular portion being evertable or everted into the first tubularportion so as to provide the double concentric tube.

It will be appreciated that it will not be necessary in all cases tohave both of the outer and inner coupling elements connected to amembrane as a fluid-tight coupling could be provided by a membranecovering only the outer coupling element, for example in cases in whichthe prosthetic sections to be coupled together themselves provide for afluid-tight coupling at the side of the inner coupling element. Thismight also apply in cases in which the coupling element is provided overa single prosthetic module, for instances in applications in which thecoupling is used in the fitting of a prosthetic element in a vessel ofinner diameter larger than the outer diameter of the prosthesis.

It is preferred that at least the outer coupling element is located onan exterior surface of the membrane, although this is not essential.

According to another aspect of the present invention, there is provideda prosthesis including a coupling device as specified herein.

According to another aspect of the present invention, there is provideda method of forming a coupling device as specified herein, including thesteps of providing a membrane of unitary structure formed of first andsecond tubular portions in which the first tubular portion has a largerdiameter than the second tubular portion and a connecting piece betweenthe first and second tubular portions; the method including the steps ofconnecting to the first and second tubular portions first and secondcoupling elements, everting the second tubular portion into the firsttubular portion so as to provide the double concentric tube with firstand second coupling elements located concentrically thereon.

The connecting piece may be sutured, welded or adhered to the outertubular portion. In a preferred embodiment, the connecting piece has afrusto-conical shape.

It will be appreciated that the term concentric used herein is notintended to be limited to elements exactly superimposed on one another.It is envisaged, for example, that the first and second couplingelements could be of different longitudinal dimensions and/or could belongitudinally offset relative to one another. The term concentric istherefore intended to include arrangements in which the inner and outerconnecting elements at least partially overlap concentrically.

The preferred embodiments provide a coupling element which has a degreeof adjustability in the radial direction, in that the outer connectingelement can expand outwardly to abut a vessel wall, while the innerconnecting element extends inwardly thereof to couple to one or moreprosthetic elements or modules. Thus, it is not necessary to size theprosthetic module precisely to the dimensions of the vessel, it beingpossible to chose a prosthetic element of smaller diameter than thevessel and still achieve, through the coupling device, a fluid-tightseal.

In practice, the space between the inner and outer coupling elementswill be filled with vascular fluid, aiding in the sealing on thecoupling and prosthesis to the vessel.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the present invention are described below, by way ofexample only, with reference to the accompanying drawings, in which:

FIG. 1 shows an example of use of an embodiment of coupling device forconnecting together modules of a branched stent-graft located within thesuperior mesenteric and iliac arteries;

FIG. 2 is a perspective view of the preferred embodiment of couplingdevice;

FIG. 3 is a perspective view of the connecting device of FIG. 2 duringmanufacture thereof; and

FIG. 4 is an enlarged view of the device of FIG. 3 in the final step ofmanufacture.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to FIG. 1, there is shown a double branched stent-graft 10located within the superior mesenteric artery 12, just below the renalarteries 14, 16, and branching into the common iliac arteries 18 and 20.The stent graft 10 branches a second time, into the femoral artery 22.

For this purpose, the stent graft 10 is formed as two modules 24, 26which are coupled to one another by an embodiment of coupling device 28of the type taught herein and described in further detail below.

In this instance, an aneurysm 30 is located in the superior mesentericartery 12, which has been isolated by the upper body portion 40 of thestent-graft 10, as well as a smaller aneurysm 32 in the iliac artery 18,at the location of the connection 34 between the two stent-graft modules24, 26.

A conventional modular stent-graft 10 would couple the two modules 24,26 by overlapping these and causing the inner-most section to expandagainst the outer section. For this purpose, the stent-graft sections ofthe modules 24, 26 would be conventionally sized to achieve a reliableand fluid-tight connection with one another.

As will be apparent from the example of FIG. 1, a conventional couplingbetween the stent-graft modules 24, 26 would not provide a fluid-tightseal around the connection zone as a result of expansion of the artery18 due to the local aneurysm.

The teachings herein provide for a different coupling between thestent-graft modules 24, 26. FIG. 1 shows the preferred embodiment ofcoupling device 28 in situ. As can be seen, the coupling device 28 fillsthe space between the stent-graft sections of the modules 24, 26 and thevessel wall so as to provide for a fluid-tight coupling with the vesselwall, as well as a fluid-tight coupling between the stent-graft sectionsof the modules 24, 26. This is possible due to the radial volumeachievable by the coupling by its ability to expand outwardly towardsthe vessel yet to retain a narrower inner diameter for the modules 24,26.

As will become apparent from the description which follows, the couplingdevice 28 is able to expand to accommodate different sizes of vessel aswell as different sizes of modules 24, 26. This property gives it alsoan adaptability lacking in existing prosthetic devices of this nature.

Referring now to FIG. 2, there is shown in better detail the embodimentof coupling device 28 shown in FIG. 1. The device 28 is formed of adouble tubing 50 of a substantially non-porous membrane material,typically a conventional graft material, providing inner and outerlayers of membrane material 52 and 54 respectively. The inner and outerlayers 52, 54 are coupled by bridging rings 56, 58 which allow thelayers 52, 54 to be spaced from one another in use.

Attached to the inner and outer layers 52, 54 are first and secondstents 60, 62 respectively. In this embodiment, the stent 60 is locatedon the inside of the double tubing, connected thus to the inner side ofthe inner layer 52. On the other hand, the stent 62 is located on theoutside of the double tubing 50, connected thus to outer side of theouter layer 54. In this manner, the inner surfaces of the double tubing50, which connect with the stent-graft modules, are free of surfacestents, which can facilitate the creation of a fluid-tight seal betweenthe stent-graft modules 24, 26 and the coupling device 28. The stentsmay be both self-expanding but this is not necessary. The stents may beof Ntitinol.

It is not necessary for the stents to be located on any particularsurface of the tubings 60, 62 and they may, for example, both be onoutside surfaces or both on internal surfaces of the tube layers. Thechoice will be dependent upon preference.

FIG. 2 shows the double tubing 50 provided with a single stent 60, 62for each tubing layer 52, 54, located substantially at the centre ofeach layer. This allows the outer layer 54 to expand outwardly and theinner layer 52 to contract inwardly, so as to cause the tubing in effectto “bulge” and thus to fill the gaps to the vessel wall and to thestent-graft sections 24, 26. In some embodiments, there could beprovided more extensive stenting of the tubular layers 52, 54, forexample by provision of a plurality of stents per layer, extending for agreater proportion and in some instances substantially for the entirelength of the tube layers 52, 54. Additional stenting can provide moreeven expansion/contraction along the length of the connector 28. Ifnecessary, the bridging rings 56,58 could be made wider to accommodategreater bulging of the connector 28 or could be expandable, for exampleby being folded in concertina manner.

The stent 62 and outer tube layer 54 are of dimensions such that theycan fit within a vessel 18 and expand to the vessel wall, including inthe location of an aneurysm 32, so as to abut thereto in a fluid-tightmanner. The stent 60 and inner tubing layer 52 are of dimensions thatthey can remain relatively contracted, or expand radially inwardly, soas to abut in fluid-tight manner, the stent-graft sections of theprosthetic modules 24, 26.

Referring now to FIG. 3, there is shown an embodiment of a preferredmethod of manufacturing the coupling device 28.

In this embodiment, the tubular element 50 is formed as a unitarystructure of graft-like material having at one end the outer tubularlayer 54 and at the other end the inner tubular layer 52. Coupling theouter and inner layers 54, 52 is a frusto-conical section forming thebridge 58. At the other end of the inner tubular layer 52 there isprovided a flared portion forming, after manufacture, the bridgingelement 56.

The stents 60, 62 are then fitted to the tubular elements 52, 54, bystitching or by any other method known in the art or otherwise suitablefor the purpose.

After fitting of the stents 60, 62, the narrower end of the structure50, that is the inner tubular layer end, is everted, in the direction ofthe arrow 70 in FIG. 3 and in so doing drawn into the outer tubularlayer 54. The step of eversion brings the outer and inner layers 52, 54into a coaxial arrangement, with the flared end exiting beyond the freeend of the outer tubular layer 54. The flared end 56 can then bestitched by suitable sutures 72 to complete the structure. The locationof the suture line 72 is not critical and can be chosen to be at anypreferred location at the end of the structure 50 or around the inner orouter layers 52, 54 by suitable choice of the respective lengths of thematerial forming the flange 56 and wider portion 54.

The completed coupling device 10 is such that the inner and outer layers52, 54 can expand in different ways, as indicated above, as they are inpractice substantially independent of one another. The structure cantherefore be made to “bulge”, that is such that the outer layer 54expands outwardly while the inner layer 52 contracts inwardly or retainsa smaller diameter.

In one particular example, the coupling device 28 has an outer diameterof 16 mm and an inner diameter of 9-10 mm. The dimensions will bedependent upon the particular medical application.

In practice, when in situ, the coupling device 28 will fill withvascular fluid, that is in the chamber formed between the inner andouter layers 52, 54, as a result of the slightly porous nature of themembrane forming the tubular element 50. This has the benefit ofassisting the seal against fluid flow around the coupling device 28,that is between the vessel wall and the outer layer 54 of the tubularstructure 50.

The device is advantageously fitted first into a patient's vasculature,in the example of FIG. 1 at the location of the aneurysm 32 in the iliacartery 18, and allowed to expand such that the outer tubular layer 54abuts and is held against the vessel wall. The stent-graft 10 is thenfitted, typically by first fitting the upper module 24 and then thelower module 26. The respective branches of the modules 24, 26 arelocated within the coupling device 28 and then expanded to abut againstand connect to the inner tubular layer 52, so as to be coupledsubstantially in fluid-tight manner thereby.

Fixing elements of known form, such as barbs may be provided on thestent-graft sections and/or on the coupling device 28 in order to securethe connection, although in many cases this would not be necessary.

The coupling device could also be used in other applications. Oneexample is for use in healthy vessels having a larger diameter than astent-graft or other prosthesis to be fitted in the vessel, another isfor application in a vessel having a reducing diameter along the lengththereof to be fitted with such a prosthesis. In the latter example, thecoupling device could usefully be located at an area in the vesselhaving a wider diameter, thus allowing the use of a stent-graft, forexample, of diameter smaller than the wider part of the vessel.

Although the embodiment shown in FIGS. 1 to 4 provides a coupling devicewhich is covered completely with a membrane 50, this is not essential inall applications. For example, it is envisaged that in some applicationsthe membrane might not extend fully into the inner layer 52, for exampleto leave the stent 60 thereof partially exposed. In such an event, it isenvisaged that the modules 24, 26 coupled by the device 28 would providethe required inner seal.

It is also envisaged that the membrane need not be an integral part ofthe coupling device 28. For example, it is possible for the couplingdevice 28 to be formed as a double layered flexible framework with innerand outer stent sections 60, 62 and for the device to make use of agraft material provided at one end, for example, of one of the modulesto be connected by the coupling element 28.

1. A coupling device for a prosthesis comprising inner and outercoupling elements arranged concentrically one within the other, thecoupling elements have a contracted condition and an expanded condition;and a substantially non-porous membrane covering at least the outercoupling element; wherein the outer coupling element is self-expandable;the inner and outer coupling elements being able to expand to differentdiameters and to be spaced from one another when expanded, such that inuse the outer coupling element expands to abut a vessel wall, while theinner coupling element extends inwardly thereof to couple to one or moreprosthetic modules, wherein the outer coupling and inner coupling areradially spaced from one another by a first distance in the contractedconfiguration and by a second distance in the expanded configuration,and where the second distance is greater than the first distance.
 2. Adevice according to claim 1, where the outer coupling element providesfor connection to a vessel wall and the inner coupling element providesfor connection to a prosthesis.
 3. A device according to claim 2, wherethe inner coupling element is self-expandable.
 4. A device according toclaim 1, where the inner coupling element is self-expandable.
 5. Adevice according to claim 1, where the inner and/or outer couplingelements are stents.
 6. A device according to claim 1, where the deviceincludes a membrane covering both the inner and outer coupling elements.7. A device according to claim 6, where the membrane is in the shape ofa double concentric tube connected at either end, the inner and outercoupling elements being located, respectively, on the inner and outerlongitudinal extents of the double tube.
 8. A device according to claim1, where the membrane is of a graft material.
 9. A device according toclaim 1, where the membrane forms part of the coupling device.
 10. Adevice according to claim 1, where the device includes a membranecovering both the inner and outer coupling elements.
 11. A deviceaccording to claim 10, where the membrane is in the shape of a doubleconcentric tube connected at either end, the inner and outer couplingelements being located, respectively, on the inner and outerlongitudinal extents of the double tube.
 12. A device according to claim10, where the membrane is a unitary structure formed of first and secondtubular portions in which the first tubular portion has a largerdiameter than the second tubular, the second tubular portion beingevertable or everted into the first tubular portion so as to provide thedouble concentric tube.
 13. A device according to claim 1, where atleast the outer coupling element is located on an exterior surface ofthe membrane.
 14. A prosthesis including a coupling device of claim 1.15. A method of forming a coupling device, including the steps of:providing a membrane of unitary structure formed of first and secondtubular portions in which the first tubular portion has a largerdiameter than the second tubular portion and a connecting piece betweenthe first and second tubular portions; the method further including thesteps of: connecting to the first and second tubular portions first andsecond coupling elements, everting the second tubular portion into thefirst tubular portion so as to provide a double concentric tube withfirst and second coupling elements located concentrically thereon, thefirst and second coupling elements being able to expand to differentdiameters and to be variably spaced from one another when expanded, suchthat in use the outer coupling element expands to abut a vessel wall,while the inner coupling element extends inwardly thereof to couple toone or more prosthetic modules.
 16. A method according to claim 15,where the connecting piece has a tapering shape.
 17. A method accordingto claim 15, where the connecting piece is sutured, welded, or adheredto the outer tubular portion.